Snowmobile Arctic Cat 2-Stroke (2007 year). Manual - part 107

8-48

Drive Train/Brake Disc

(F-Series)

Removing Gear Case ........................................... 8-48
Removing Track Driveshaft  .................................. 8-49
Installing Track Driveshaft  .................................... 8-51
Disassembling Gear Case .................................... 8-52
Cleaning and Inspecting Gear Case ..................... 8-55
Removing Drive Sprockets.................................... 8-55
Installing Drive Sprockets...................................... 8-56
Assembling Gear Case ......................................... 8-57
Installing Gear Case ............................................. 8-60

REMOVING GEAR CASE

„NOTE: The gear case drive fluid does not have to
be drained for this procedure.

1. Remove the access panels from both sides of the

snowmobile.

„NOTE: At this point, engage the brake lever lock.

2. Using a 9/16-in. socket and extension, remove the

cap screw securing the driven pulley to the input

shaft. Remove the pulley from the shaft.

ZJ182A

„NOTE: After removing the driven pulley, account
for the cap screw and washers, sheave adjuster,
alignment washers, and O-ring from outside the
pulley; then from the input shaft, remove the two
1.5 mm (0.060 in.) washers along with any other
alignment washers. These washers must be used
during installing.

3. Disconnect the plug-ins for the shift actuator (A)

and the gear indicator switch (B).

ZJ183A

4. Remove the torx-head cap screws securing the toe

shield and hook bracket to the chassis; then

remove the shield and bracket.

0742-089

„NOTE: Either elevate the snowmobile off the floor
with a suitable lift or tip the snowmobile on its
right side positioning the gear case side of the
snowmobile up. Place a piece of cardboard under
the side of the snowmobile to prevent scratching
of bumper and belly pan.

5. Loosen but do not remove the 16 mm cap screw

(from the brake disc side of the inner driveshaft)

securing the driveshaft to the gear case.

. 

742-020A

„NOTE: For gear case removing purposes at this
time, do not remove the 16 mm cap screw.

8-49

8

6. Remove the seven lock nuts securing the gear case

to the chassis; then remove the remaining lock nut

and torx-head cap screw.

 

742-018A

7. Place the snowmobile in the upright position; then

using a 16 mm socket, long extension, and a soft

hammer, tap against the driveshaft cap screw until

the gear case is free from the studs of the mounting

plate.

8. Remove the cap screw from the inner driveshaft

(from step 5); then remove the gear case. 

„NOTE: If the gear case is difficult to remove, it
may be necessary to loosen the track tension.

„NOTE: Account for the torque bumper.

REMOVING TRACK DRIVESHAFT 

„NOTE: The gear case drive fluid does not have to
be drained for this procedure.

1. Remove the access panels from both sides of the

snowmobile.

2. Remove the negative cable from the battery; then

remove the positive cable. Remove the hardware

securing the battery to the tray; then remove the

battery.

3. Remove the hairpin clip and springs securing the

resonator; then remove the resonator from the

engine compartment.

4. Remove the two cap screws securing the speedom-

eter sensor bracket. Account for two spacers.

ZJ210A

5. Loosen but do not remove the 16 mm cap screw

(from the brake disc side of the inner driveshaft)

securing the driveshaft to the gear case.

742-020A

„NOTE: For gear case removing purposes at this
time, do not remove the 16 mm cap screw.

6. Using Brake Disc Socket Wrench (p/n 0644-481),

remove the retaining nut from the driveshaft.

ZJ211

7. Using the Rear Suspension Spring Tool (p/n 0144-

311), remove the spring from the adjusting cam.

8. Remove the rear cap screws securing the skid

frame to the tunnel. Account for lock washers and

flat washers.

! WARNING

Care must be taken when removing the spring or
damage or injury could result.

8-50

9. Tip the snowmobile onto the right side positioning

the gear case side of the snowmobile up. Place a

piece of cardboard under the side of the snowmo-

bile to protect against scratching. 

10. Slide the skid frame rearward far enough to drop

the front arm out of the slider axle; then remove

the skid frame.

11. Using a 9/16-in. socket and extension, remove the

cap screw securing the driven pulley to the input

shaft.

ZJ182A

12. Slide the driven pully off the shaft.

„NOTE: After removing the driven pulley, account
for the cap screw and washers, sheave adjuster,
alignment washers, and O-ring from outside the
pulley; then from the input shaft, remove the two
1.5 mm (0.060 in.) washers along with any other
alignment washers. These washers must be used
during installing.

13. Disconnect the plug-ins for the shift actuator (A)

and the gear indicator switch (B).

ZJ183A

14. Remove the torx-head cap screws securing the toe

shield and hook bracket to the chassis; then

remove the shield and bracket.

0742-089

15. Remove the seven lock nuts securing the gear case

to the chassis; then remove the remaining lock nut

and torx-head cap screw.

742-018A

16. Place the snowmobile in the upright position; then

using a 16 mm socket, long extension, and a soft

hammer, tap against the driveshaft cap screw until

the gear case is free from the studs of the mounting

plate.

17. Remove the cap screw from the inner driveshaft

(from step 5); then remove the gear case. 

„NOTE: If the gear case is difficult to remove, it
may be necessary to loosen the track tension.

„NOTE: Account for the torque bumper.

18. With the gear case removed, pull the driveshaft

toward the gear case side of the tunnel until it

clears the brake caliper housing; then remove the

driveshaft. Account for the rubber seal.

ZJ212

8-51

8

INSTALLING TRACK DRIVESHAFT 

„NOTE: Prior to installing the driveshaft, apply a
coat of Anti-Seize Thread Compound (p/n 0678-
146) to the internal splines of the driveshaft.

ZJ213A

1. Place the track/driveshaft assembly into the bear-

ing of the brake housing just far enough to allow

the brake disc to be installed in the brake housing

assembly. 

ZJ214A

„NOTE: Prior to installing the driveshaft, ensure
that the bearing spacer is positioned to the inner
bore of the brake caliper housing.

0742-087

2. With the brake lever lock engaged and the brake

disc correctly positioned in the brake housing

assembly, properly align the splines of the drive-

shaft with the brake disc; then push the driveshaft

the rest of the way into the brake housing until it is

properly seated.

ZJ215A

„NOTE: Prior to placing the gear case onto the
driveshaft, apply a light coat of Anti-Seize Thread
Compound (p/n 0678-146) to the splines of the
driveshaft.

3. Place the gear case onto the driveshaft; then press

the gear case toward the sprocket until it properly

seats into place on the chassis. It may be necessary

to rotate the driveshaft slightly for proper seating.

4. Loosely secure the gear case by first installing the

six lock nuts and finger tighten; then install the

torque bumper and a torx-head cap screw and the

two remaining lock nuts and tighten all the nuts to

specifications.

742-018A

„NOTE: When tightening the nuts to the proper
torque factor, it is advisable to begin tightening the
nuts located on the bottom of the gear case and
working upward in a crisscross pattern until all
nuts are tightened to the proper torque factor.

5. Connect shift actuator harness (A) and gear indica-

tor switch harness (B).